Single-walled connecting key framesets

ABSTRACT

Frames and processes of manufacture using single-wall frame sections coupled to other single-wall frame sections or double-wall frame sections using a connecting key are provided. The connecting key can be metallic, polymer, ceramic, a laminate, and combinations thereof.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/370,565, which was filed on Mar. 29, 2019 and issued as U.S. Pat No.10,935,282 on Mar. 2, 2021. '565 application claims priority toprovisional application 62/651,035, which was filed on Mar. 30, 2018 andis entitled Single-Walled Connecting Key Framesets. The '035 applicationis incorporated herein in its entirety by reference.

BACKGROUND

Photovoltaic (PV) cells, commonly known as solar cells, are devices forconversion of solar radiation into electrical energy. Generally, solarradiation impinging on the surface of, and entering into, the substrateof a solar cell creates electron and hole pairs in the bulk of thesubstrate. The electron and hole pairs migrate to p-doped and n-dopedregions in the substrate, thereby creating a voltage differentialbetween the doped regions. The doped regions are connected to theconductive regions on the solar cell to direct an electrical currentfrom the cell to an external circuit. When PV cells are combined in anarray such as a PV module, the electrical energy collected from all ofthe PV cells can be combined in series and parallel arrangements toprovide power with a certain voltage and current.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate cross-sectional views of double -wall andsingle-wall frame sections as can be employed, according to someembodiments.

FIG. 2 illustrates a perspective view of a single-wall/double-wall keyas can be employed, according to some embodiments.

FIG. 3 illustrates a perspective corner view of a single-wall framesection joined to a double-wall frame section using a connecting keywith screw fasteners as can be employed, according to some embodiments.

FIG. 4 illustrates the same perspective corner view as FIG. 3 and alsoincludes ghost lines to illustrate details of the connecting key and itssecurement of the two frame sections as can be employed, according tosome embodiments.

FIG. 5 illustrates a perspective corner view of a single-wall framesection to be joined to a double-wall frame section using a connectingkey with alignment tabs and a constraining protrusion as can beemployed, according to some embodiments.

FIG. 6 illustrates the same perspective corner view as FIG. 5 and alsoincludes ghost lines to illustrate details of the connecting key and itssecurement of the two frame sections as can be employed, according tosome embodiments.

FIG. 7 shows a perspective cut-away view of a single-wall frame sectionjoined to a single-wall frame section using a connecting key as can beemployed, according to some embodiments.

FIG. 8 illustrates the same perspective corner view as FIG. 7 and alsoincludes ghost lines to illustrate details of the connecting key and itssecurement of the two single-wall frame sections as can be employed,according to some embodiments.

FIG. 9 illustrates details of the connecting key from FIG. 7 and FIG. 8.

FIGS. 10A-10C illustrate a connecting key with various clipconfigurations as can be employed, according to some embodiments.

FIG. 11 illustrates a plan view of a connecting key serving as a centralhub for six frame sections as can be employed, according to someembodiments.

FIG. 12 illustrates a side elevation view of a frame section as can beemployed, according to some embodiments.

FIGS. 13A and 13B illustrate the seating or connection of a tab andrecess as can be employed, according to some embodiments.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments the application and uses ofsuch embodiments. As used herein, the word “exemplary” means “serving asan example, instance, or illustration.” Any implementation describedherein as exemplary is not necessarily preferred or advantageous overother implementations. Furthermore, there is no intention to be bound byany expressed or implied theory presented in the preceding technicalfield, background, brief summary or the following detailed description.

References to “one embodiment” or “an embodiment” do not necessarilyrefer to the same embodiment. Particular features, structures, orcharacteristics can be combined in any suitable manner consistent withthis disclosure.

Terminology. The following paragraphs provide definitions and/or contextfor terms found in this disclosure (including the appended claims):

“A”, “an”, “the”. As used herein, the singular forms “a,” “an” and “the”are intended to include plural forms as well, unless the context clearlyindicates otherwise.

“About” or “Approximately”. As used herein, the terms “about” or“approximately” in reference to a recited numeric value, including forexample, whole numbers, fractions, and/or percentages, generallyindicates that the recited numeric value encompasses a range ofnumerical values (e.g., +/−5% to 10% of the recited value) that one ofordinary skill in the art would consider equivalent to the recited value(e.g., performing substantially the same function, acting insubstantially the same way, and/or having substantially the sameresult).

“Comprising” is an open-ended term that does not foreclose additionalstructure or steps.

“Configured to” connotes structure by indicating a device, such as aunit or component, includes structure that performs a task or tasksduring operation, and such structure is configured to perform the taskeven when the device is not currently operational (e.g., is noton/active). A device “configured to” perform one or more tasks isexpressly intended to not invoke 35 U.S.C. § 112, (f) or sixthparagraph.

“First,” “second,” etc. terms are used as labels for nouns that theyprecede, and do not imply any type of ordering (e.g., spatial, temporal,logical, etc.). For example, reference to a “first” frame connecting keydoes not necessarily imply that this frame connecting key is the firstframe connecting key in a sequence; instead the term “first” is used todifferentiate this connecting key from another connecting key (e.g., a“second” connecting key).

“Based On.” As used herein, this term is used to describe one or morefactors that affect a determination. This term does not forecloseadditional factors that can affect a determination. That is, adetermination can be solely based on those factors or based, at least inpart, on those factors. Consider the phrase “determine A based on B.”While B can be a factor that affects the determination of A, such aphrase does not foreclose the determination of A from also being basedon C. In other instances, A can be determined based solely on B.

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature, and not necessarily mechanically.

“Inhibit” describes a reducing, lessening, minimizing, or effectively oractually eliminating something, such as completely preventing a result,outcome or future state completely.

In addition, certain terminology can also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper”, “lower”, “above”,and “below” refer to directions in the drawings to which reference ismade. Terms such as “front”, “back”, “rear”, “side”, “outboard”, and“inboard” describe the orientation and/or location of portions of thecomponent within a consistent but arbitrary frame of reference which ismade clear by reference to the text and the associated drawingsdescribing the component under discussion. Such terminology can includethe words specifically mentioned above, derivatives thereof, and wordsof similar import.

In the following description, numerous specific details are set forth,such as specific operations, in order to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to one skilled in the art that embodiments of the presentdisclosure can be practiced without these specific details. In otherinstances, well-known techniques are not described in detail in order tonot unnecessarily obscure embodiments of the present disclosure.

PV modules can include glass laminates comprising an array of PV cellsalong with a microinverter receiving a DC voltage from the PV cells andcabling supplying the output from the microinverter to a load or otherexternal recipient. The glass laminates of the PV modules can besurrounded by a metal frame, which can be referred to herein as a PVframe or a frame, and the microinverter and the cabling can be securedto this metal frame. The metal frame can, in-turn, be used to secure thePV module with microinverter and cabling to a support structure.

Embodiments can include sectional PV frames and processes of manufacturewhereby single-wall frame sections are coupled to other single-wallframe sections or to double-wall frame sections using one or moreconnecting keys. The connecting keys can be metallic, polymer, ceramic,laminate, and combinations thereof. In other words, the connecting keyscan include one or more materials and these materials can be integratedwith each other to form an homogenous material or can be layered as acomposite material, e.g., a metallic shell with a polymer insert, ametallic shell with a ceramic insert, or a ceramic layer coupled to apolymer layer, which is itself coupled to a metallic layer, etc. Theconnecting keys can be fashioned such that they can be secured to one ortwo or more PV frame sections using the same connection methodologies orusing different connection methodologies. In other words, for example,when connecting two frame sections together, a connecting key can besecured to a single-wall frame segment using screws, rivets, welding, aconstraining protrusion, frictional tight-fit engagements, or othermechanical or chemical fastening systems, or combinations thereof, andcan be secured to a double-walled frame section using these same orother connection techniques as well. A frictional tight-fit connectioncan be made during a subsequent assembly stage or in the field prior toinstallation, as well as during an earlier assembly stage or process.

Assembled framesets, i.e., when more than one single-walled ordouble-walled frame sections are coupled together, can include variousshapes including single polygons such as squares, pentagons, andtriangles as well as multiple single polygons grouped together. In someembodiments the frame sections can be curved and assembled framesets caninclude curved and straight frame sections as well as all curved framesections, or all straight frame sections, with one or more of the curvedor straight frame sections being joined by connecting keys. Moreover,connecting keys in embodiments can also serve as central hubs andin-line connectors in addition to serving as corner connectors. Forexample, when connecting three or more frame sections, as can beemployed in a central hub of a multiple polygon framing system, aconnecting key can be configured to connect three single-wall framesections, a double-wall frame section, and three triple wall framesections, or other combinations of frame sections. For example, as isshown in FIG. 11 , a connecting key 1110 can have a central section andsix outwardly extending arms 1112, 1113, where each arm 1112, 1113, isconfigured as described herein to secure to either single-wall 1120,double-wall 1130, or triple-wall 1140, framing segments. Embodiments canemploy connecting keys with fewer or more arms than those shown in FIG.11 .

The connecting keys and the frames can include alignment tabs such as651 of FIG. 6 and corresponding alignment recesses or voids in theframes such as 550 in FIG. 5 , to assist in assembly and alignment. Inthese and in other embodiments, assembly can be assisted by thealignment tab moving during a securement step, e.g., through deflection,and then having the tab return to an original or near original positionwhen a connecting key arm or other portion and a frame section or othercomponent are joined. FIGS. 13A-13B illustrate tabs before and aftermating with a corresponding alignment recess. Additional securement,such as fasteners (e.g., screws, rivets, pins) as well as welding,adhesives, and other features mentioned herein, or combinations thereof,can also be employed to secure or permanently secure a connecting key toa particular frame segment.

In embodiments, frame sections can be designated herein as short sideand long side segments to denote a relative comparison between framesegments of the same or different frames. Also, embodiments can employconnection features that do not occupy the entire length of a framesection. In other words, when frame sections are extruded, embodimentscan employ connecting features at the ends of each frame section thatare not maintained along the entire length of the frame section but are,instead, solely located at or near the ends of the frame section. Theseconnecting features can include alignment tabs and alignment recesses inone or both of the frames and the connecting keys. For example,referring to FIGS. 1A-1B, the flange cap end 114 and 124 and the turnedflange end 129, 133 may not exist along an entire length of a framesection 120, 110, but, can, instead only be located at the ends of aframe section and/or interim middle portions, to allow the section to becoupled to and by a connecting key. FIG. 12 shows an example of how aflange cap end 1224 and a turned flange 1229 can occupy only a portionof the length of a frame section 1220. Also labelled in FIG. 12 are theweb 1223, the end cap web 1230 and the turned flange 1231. Similarly,the flange cap 116 and 126 of FIGS. 1A-1B may not be present along anentire length of a frame section, and can, instead, be located at setdistances along the length of the frame section, for an example, everytwo inches, an inch of flange cap can exist; other space lengths andflange cap lengths can be used.

In embodiments, connecting keys can be secured to one or more framesections using aluminum bonding techniques that work for anodizedsurfaces as well as, or in addition to, formed fittings (e.g., Toxfittings), advanced welds (e.g., stir) and advanced adhesives or theother securement systems identified herein, e.g., adhesive bars. Othersecurement methods and means can also be used, as well as combinationsof securements.

In embodiments, during assembly, a connecting key can be secured to asingle-wall segment using one or more of the securement methodsdescribed herein as well as other techniques and configurations. Later,this single walled frame section can be joined with a double-walledsection by pressing an arm of the connecting key into the frame sectionbeing joined. If the section to be joined is a single wall section, thenfriction securement systems, in addition to press fitting or instead ofpress fitting, can be employed. For example, the connecting key can beslid into the channel 128 of FIG. 1B and secured against the web 123 andthe flange cap end 124 and the turned flange end 129 as a press fitconnection. A connecting key can also be secured to a web 123 or otherportion of a single wall frame section with adhesives, screws, or otherconnection techniques, such as those as mentioned herein.

Embodiments can preferably provide electrical continuity between framesections being connected. Continuity features can include conductingstrips in connection keys as well as locking features of two wallsections to be joined so that electrical conductivity between framesegments is preferably maintained after the frameset is assembled. Theconnecting keys can include clips, as shown in FIGS. 10A-10C, which canserve to scratch the surface of an adjoining frame section when theconnecting key is mated with the frame section. This surface scratchingcan provide electrical continuity through the connecting key and betweenjoined frame sections. Thus, a connecting key can be joined to anodizedaluminum framesets in many ways. These can include, but are not limitedto, friction fit, clips, screwing, riveting, welding, bending, clinching(Tox), or the use of adhesives, or a combination of these. Many of thesemethods can likewise provide electrical ground continuity via theconnecting key as well, including if a conductive adhesive was used oncoating abrasions on portions of the frame. For example, in embodiments,a frame section can be pressed into an adjacent double walled framesection that can be installed on a long side of a PV laminate providingcontinuity and mechanical bonding between the joined frame sides. Thiscan result with embodiments in framesets (e.g., single wall/double wall)that have reduced material costs from purely double wall frame sets andcan have sufficient continuity between joined frame sections.

As another example, in embodiments, a single-wall short side framesetcan be coupled to a connecting key using one of these methods in akitting process performed by a manufacturer. In an example, a kittingprocess can include gathering the components needed for an assembly andplacing them together in a single kit for use at the job site duringinstallation. These kits can include some assembled components whileother components are not connected and left for assembly in the field orat a later stage.

Turning now to FIGS. 1A-1B, which illustrate cross-sectional views ofsingle-wall 120 (FIG. 1B) and double-wall 110 (FIG. 1A) frame sectionsas can be employed in some embodiments. As can be seen, each framesection includes a flange 111, 121, 121, 131 and an exposed flangechannel 132 for receiving a PV laminate edge. A frame hollow 112,between both webs 113 of the double-wall frame section 110, is alsoshown. In embodiments, these frame sections can have various lengths,including approximately in the range of 0.25 meters-2 meters or more andintervening sizes in increments of 0.1 meters or less. Also labelled inFIG. 1 are flange end cap 116, flange end cap 126, rounded flange capend 117, rounded flange cap end 127, straight flange cap end 114,straight flange cap end 124, end cap web 130, 119, web reinforcement133, web 113, web 123, frame hollow 112, turned flange end 129, 134, andflange recess 125. Flange cap ends 117, 127, 114, and 124 can be rounded(as illustrated in flange cap ends 117 and 127) or straight (asillustrated in flange cap ends 114, 124) or have other configurations aswell. Likewise, other ends of frame sections 110, 120, regardless ofwhether designated by numerals herein, can be rounded or straight.

In embodiments, and as noted above, connecting keys can have arms thatengage through friction and/or connectors, such as screws or toxfittings, or rivets, or other connector schemes, or combinationsthereof, to portions of a frame section, e.g., 110 and 120 of FIGS.1A-1B. In embodiments, a key, such as key 210 of FIG. 2 , can engage theweb 113, 123, or slide into an exposed flange channel 128, or engageboth, when connecting frame sections. As noted above, the key canprovide an electrical continuity for grounding or other purposes betweenconnected frame sections. The continuity can be provided by connectorsof the key and by other structures as well.

In embodiments, the channel of a frame section, e.g., 132 of FIGS.1A-1B, can be sized to accept an edge or other portion of a photovoltaic(PV) laminate in order to support or reinforce the PV laminate. As canbe seen in FIGS. 1A-1B, the flange cap end 114, 124 and the turnedflange end 134, 129 can be positioned opposing each other and about thesame distance: d from a web 113, 123 in order to create an exposedchannel 128 for accepting a connecting key. Moreover, the distance d canbe used when adding a connecting key or splitting a connecting keyaround a central web or other wall. In certain embodiments, for fitmentpurposes the central wall or web 123/132 can be punched away, otherwiseremoved, or shifted such that a key portion can be positioned somewherebetween the two 113 walls on the double walled section.

FIG. 2 illustrates a perspective view of a single-wall/double-wallconnecting key 210 as can be employed, according to some embodiments. Inan embodiment, this connecting key 210 is a single-wall key with twoconnecting holes 213. In an embodiment, the single-wall key can be asingle-wall aluminum key. Other materials, such as galvanized steel, orcarbon laminate, or polymers, can also be used. Additionally, oneconnecting hole, or more than two connecting holes, such as 3, 4, 5, ormore connecting holes, can be employed in embodiments. These connectingholes 213 can be used to secure the key to a single wall frame sectionduring manufacture. In an example, the connecting holes can instead bereferred to as screw holes, and screws can be used as connectors;however, the connecting holes can have other configurations, such as arod-hole combination, a pin-hole combination, a rivet-hole combination,a tox-hole combination, and a tab- or flange-slot/recess combination,and combinations thereof. Once connected the end of the key with theteeth or friction fins 215 can be slid into the frame hollow 112 of thedouble wall section shown in FIG. 1A or can be slid into the exposedflange channel 128 of either of the double wall section of FIG. 1A orthe single wall section of FIG. 1B. The teeth 215 of the key 210 canengage the web 113, 123 of a frame as well as other portions of theframe sections and thereby serve to frictionally connect a single wallframe section to a double-wall frame section, or to connect twodouble-wall frame sections or two single-wall frame sections.

Also labelled in FIG. 2 are an open-end hollow 214, pinching ends 217,long key arm 219, optional key hollows 211, 212, 220, short key arm 218,and edge key arm 216. In some embodiments, a key arm can be sized to fitand engage an exposed flange channel 128 of either a single wall framesection 120 or a double wall frame section 110. In some embodiments, theconnecting key can have two short key arms, two long keys arms, three ormore key arms (such as when connecting three or more frame sectionstogether), a long key arm and a short key arm, and various permutationsof these examples. As noted above, the connecting holes 213 can bethreaded to accept screws and can also be sized or configured for otherconnectors, e.g., pins, rods, rivets, tox connectors, etc. Otherconnection techniques can be used, such as a flange-slot/recesscombination or a tab-slot/recess combination.

In embodiments, connecting keys can join frame sections at variousangles that can include: 11.25°, 22.5°, 45°, 60°, 75°, 90°, 110°, 115°,125°, 135°, and 180°. The frame sections can be made from variousmaterials and can include a metal of sufficient rigidity. Inembodiments, the connecting keys and frame sections can be galvanized,anodized, or otherwise treated to resist weathering.

FIG. 3 illustrates a perspective corner view of a single-wall framesection 120 joined to a double-wall frame section 110 using a connectingkey with screws 350 along a short arm as can be employed, according tosome embodiments. The top and bottom flange sections e.g., 116, 126,121, 131, of the frame wall sections, 110, 120 are visible along withthe connectors, e.g., screws 350, securing the connecting key to thesingle wall frame section 120. The PV laminate 320 with upward facing PVcells and PV laminate edge 321 are visible in FIG. 3 and FIG. 4 .

FIG. 4 illustrates the same perspective corner view as FIG. 3 , but usesghost lines to illustrate details of the connecting key 210 and itssecurement of the two frame sections as can be employed, according tosome embodiments. Shadow or ghost lines reveal the location of theconnecting key 210 relative to the single wall frame section 120 and thedouble wall frame section 110 in FIG. 4 . The two screws 350 and theangled meeting 430 of the bottom flanges of the wall sections are alsovisible in FIG. 4 . The single wall frame 120, and double wall frame 110are each labelled in FIGS. 3 and 4 . Also labelled in FIG. 4 are the PVlaminate edge 321, the PV laminate 320, and the flange end cap 126.

FIG. 5 illustrates a perspective corner view of a single-wall framesection 120 joined to a double-wall frame section 110 using a connectingkey 610 with alignment tabs and a constraining protrusion 540 as can beemployed, according to some embodiments. Labelled in FIG. 5 are a PVlaminate 320, PV laminate edge 321, single wall frame section 120,adhesive bar 540, and alignment recesses 550.

In some embodiments, rather than or in addition to fasteners,constraining protrusions 540 can be used to secure one or more framewalls to a connecting key. These protrusions 540 can form abutments uponwhich connecting keys or features of the adjoining frame section canpress against. The constraining protrusion can include a pressure fittongue that snaps into place to receive and then hold a portion of aconnecting key or feature of an adjoining frame section. Alignment tabs651 of FIG. 6 and recesses 550 of FIG. 5 can also be employed on framewalls, as well as the connecting keys to assist in alignment andsecuring the walls and keys together. During an assembly process, forexample, where a tab on a wall section meets a recess on a connectingkey, the parts can deflect and then return to an original position asthey become biased to remain in that relative orientation and furtherconnecting processes can be carried out. These further processes caninclude using fasteners to connect the two pieces together as well asusing a constraining protrusion, brazing, or another connectionmethodology. Deformable Tox connectors or other connecting schemes canbe used when aligning and securing key connectors to frame sections.FIG. 13A (during assembly view 1300) and 13B (after assembly view 1301)show the seating or connection of a tab and recess as can be employed inembodiments. FIG. 13A shows a key section 1311 with two tabs 1310 beingslid to connect with the recesses 1320 of a frame section 1321. As canbe seen, a space 1330 exists between the frame section 1321 and theconnector 1311 while the pieces are being slid together. Once connected,as shown in FIG. 13B, the tabs 1310 are positioned within the recesses1320 and no space or little space exists between the frame section 1321and the key section 1311.

FIG. 6 illustrates the same perspective corner view as FIG. 5 and alsoincludes ghost lines to illustrate details of the key and its securementof the two frame sections as can be employed, according to someembodiments. The alignment tabs 651 are labelled along with the doublewall frame section bottom flange 121, the constraining protrusion 540,PV laminate edge 321, and PV laminate 320.

FIG. 7 shows a perspective view of a single-wall frame section 120joined to a single-wall frame section 120 using a connecting key 710 ascan be employed, according to some embodiments. As can be seen in FIG. 7, the 1w/1w connecting key 710 has arms of equal length and theconnecting key 710 is configured to fit within an exposed channelbordered by top and bottom flanges of single-wall frame sections 120.This connecting key is in the form of a right angle but other angles canalso be formed by connecting keys as described herein.

As can be seen in FIG. 8 , each arm of the connecting key has arelatively thicker section 890 and a relatively thinner section 880. Thethicker section 890 can be employed for securement to the single-wallsection while the thinner section 880 can provide alignment between theconnecting key 710 and the single-wall frame section or double wallframe section as well as stiffness reinforcement to a single-wall framesection. The thinner section 880 may include an upturned end 870 toassist in inserting the arm into a frame section. When connecting aconnecting key to an exposed flange channel, such as 128 of FIG. 1B, thethinner section 880 can serve to initially align the key and frame settogether during assembly and the thicker section 890 can serve to fittightly between the flange cap end and turned flange end, e.g., 124, 129of FIG. 1B, and the web of the frame section, e.g., 123 of FIG. 1B, andsecure the key connector to the frame section after assembly and duringuse. Arms of the connecting keys can be in ranges of greater than 0.3 mm(0.0118 inches) and less than 15 mm (0.591 inches) where variousthicknesses in that range can exist in 0.1 mm (0.00394 inch) increments,including specifically 0.8 mm (0.0315 inches), 1.0 mm (0.0394 inches),6.0 mm (0.236 inches), 7.5 mm (0.276 inches), etc.

FIG. 8 illustrates the same perspective corner view as FIG. 7 and alsoincludes ghost lines to illustrate details of the connecting key and itssecurement of the two single-wall frame sections 800, as can be employedin embodiments. Visible in this perspective view are the bottom flanges820 and top flanges 811 of the frame sections, as well as hollows 871 ofkey 710. As can be seen, the bottom flange is wider than the top flangeof the frame wall sections. Also visible is that the frame sections meetat 45° mitered angles 860. These mitered joints can be other angles aswell in embodiments, and can be further reinforced, for example, withglue, soldering, and crimping or other fastening methods. In addition,the joints can have gaps between them or can meet fully. The gaps canprovide for flexion or adjustment during final assembly stages. Flexionhere can be understood to mean the action of bending or the condition ofbeing bent, for example, the bending of a joint or connection. The gapscan also allow for clips to protrude from the connecting keys and engagea web face or other portion of a frame section. Exemplary clips areillustrated in FIGS. 10A-10C.

FIG. 9 illustrates details of the connecting key 710 from FIG. 7 andfrom FIG. 8 . Visible here are the thinner section 880 and the thickersection 890 of the connecting key. The thinner section 880 can be sizedand configured to assist in positioning and inserting the key 710 into aframe section while the thicker section 890 can be sized and configuredto provide rigidity and strength for securing the connected framesections together. In embodiments, the thinner section can be on theorder of approximately 2 mm-10 mm or more while the thicker section canbe on the order of approximately 5 mm-30 mm or more. These thicknessescan be more or less and can be determined by the materials beingemployed for the connecting key and/or the frame sections. Multiplehollows 871 are also illustrated in the connecting key 710 of FIG. 9 .

FIGS. 10A-10C show a connecting key 210 with various clip configurationsas can be employed, according to some embodiments. Labelled in FIGS.10A-10C are connecting key 210, clip 1010, arched pinching clip 1020,and connecting holes 213. The clips 1010 and 1020 can be employed tocreate or reinforce electrical continuity between joined frame sections.These clips 1010 and 1020 of FIGS. 10A-10C can be formed of the samematerials as the key connectors identified above as well as differentmaterials. The frame sections can be scratched or etched by the clipsduring assembly so as to provide metal to metal conduction. The surface1011 and 1021 of FIG. 10B can scratch or etch the frames as the keyconnectors are connected to the frame sections. The frames can also becontoured or spaced so as to cover the clips or portions of the clipswhen the frames are connected with a key connector.

Although specific embodiments have been described above, theseembodiments are not intended to limit the scope of the presentdisclosure, even where only a single embodiment is described withrespect to a particular feature. Examples of features provided in thedisclosure are intended to be illustrative rather than restrictiveunless stated otherwise. The above description is intended to cover suchalternatives, modifications, and equivalents as would be apparent to aperson skilled in the art having the benefit of this disclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims can be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimscan be combined with those of the independent claims and features fromrespective independent claims can be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

What is claimed is:
 1. A photovoltaic laminate frame connecting keycomprising: a first arm having a first length; a second arm having asecond length, the second arm coupled to the first arm and defining anangle other than one-hundred eighty degrees therebetween the first armand the second arm, the second length being greater than the firstlength, wherein the first arm is configured and sized to be secured to afirst single-wall frame section of a photovoltaic laminate frame withone or more first fasteners, at least one of the one or more firstfasteners, when engaged with the first single-wall frame section, notbeing parallel to the first single-wall frame section, and wherein thesecond arm is configured and sized to be secured to a second framesection of a photovoltaic laminate frame with one or more secondfasteners.
 2. The photovoltaic laminate frame connecting key of claim 1wherein the second arm is configured and sized to be secured to thesecond frame section of the photovoltaic laminate frame with one or moresecond fasteners, at least one of the one or more second fasteners ofthe second arm, when engaged with the second frame section, not beingparallel to the second frame section.
 3. The photovoltaic laminate frameconnecting key of claim 1 wherein the second arm is coupled to the firstarm and defines an orthogonal angle between the first arm and the secondarm.
 4. The photovoltaic laminate frame connecting key of claim 1wherein the first arm and the second arm are electrically conductive. 5.The photovoltaic laminate frame connecting key of claim 1 wherein thefirst arm is configured with a tab or recess positioned to meet anopposing tab or recess on the first single -wall frame section.
 6. Thephotovoltaic laminate frame connecting key of claim 1 wherein the firstarm and the second arm comprise anodized aluminum.
 7. The photovoltaiclaminate frame connecting key of claim 1 wherein the second arm has anouter perimeter cross-section in the shape of a triangle.
 8. Thephotovoltaic laminate frame connecting key of claim 1 wherein the firstarm comprises a plurality of friction fins, pinching ends, and an openhollow at a distal end thereof.
 9. The photovoltaic laminate frameconnecting key of claim 1 wherein the second arm is configured and sizedto be secured to the second frame section of the photovoltaic laminateframe, the second frame section comprising a double-wall.
 10. Thephotovoltaic laminate frame connecting key of claim 9 wherein the secondarm is further configured and sized to be secured between walls of thedouble-wall second frame section with a frictional engagement betweenwalls of the double-wall second frame section.
 11. A photovoltaiclaminate frame connecting key comprising: a first arm having a firstlength; a second arm having a second length, the second arm coupled tothe first arm and defining an angle other than one-hundred eightydegrees between the first arm and the second arm, wherein the first armis configured and sized to be secured to a first single-wall framesection of a photovoltaic laminate frame with one or more firstfasteners, at least one of the one or more first fasteners, when engagedwith the first single-wall frame section, not being parallel to thefirst single-wall frame section, wherein the second arm is configuredand sized to be secured to a second frame section of a photovoltaiclaminate frame with one or more second fasteners, and wherein the firstarm has a first distal end and the second arm has a second distal end, ashape of the first distal end is different than a shape of the seconddistal end.
 12. The photovoltaic laminate frame connecting key of claim11 wherein the second arm is configured and sized to be secured to thesecond frame section of the photovoltaic laminate frame with one or moresecond fasteners, at least one of the one or more second fasteners ofthe second arm, when engaged with the second frame section, not beingparallel to the second frame section.
 13. The photovoltaic laminateframe connecting key of claim 11 wherein the second arm is coupled tothe first arm and defines an orthogonal angle between the first arm andthe second arm.
 14. The photovoltaic laminate frame connecting key ofclaim 11 wherein the first arm and the second arm are electricallyconductive.
 15. The photovoltaic laminate frame connecting key of claim11 wherein the first arm is configured with a tab or recess positionedto meet an opposing tab or recess on the first single -wall framesection.
 16. The photovoltaic laminate frame connecting key of claim 11wherein the first arm and the second arm comprise anodized aluminum. 17.The photovoltaic laminate frame connecting key of claim 11 wherein thesecond arm has an outer perimeter cross-section in the shape of atriangle.
 18. The photovoltaic laminate frame connecting key of claim 11wherein the second arm is configured and sized to be secured to thesecond frame section of the photovoltaic laminate frame, the secondframe section comprising a double-wall.
 19. The photovoltaic laminateframe connecting key of claim 18 wherein the second arm is furtherconfigured and sized to be secured between walls of the double-wallsecond frame section with a frictional engagement between walls of thedouble-wall second frame section.
 20. A photovoltaic laminate frameconnecting key comprising: a first arm having a first length; a secondarm having a second length, the second arm coupled to the first arm anddefining an angle other than one-hundred eighty degrees between thefirst arm and the second arm, wherein the first arm is configured andsized to be secured to a first single-wall frame section of aphotovoltaic laminate frame with one or more first fasteners, at leastone of the one or more first fasteners, when engaged with the firstsingle-wall frame section, not being parallel to the first single-wallframe section, and wherein the second arm is configured and sized to besecured to a second frame section of a photovoltaic laminate frame withone or more second fasteners and comprises a butt joint against thesecond frame section.